Insulated container

ABSTRACT

An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may be characterized by a lack of any wrapping material. The insulation layer may be manufactured using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven material for providing consistent density throughout the insulation layer. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer. The insulation layer may be biodegradable in an anaerobic environment.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 15/436,417 filed on Feb. 17, 2017, which is a non-provisionalapplication tracing priority to U.S. Provisional Application No.62/338,136, filed on May 18, 2016. This application claims the fullbenefit and priority to the 62/338,136 application and the Ser. No.15/436,417 application, both of which are herein expressly incorporatedby reference in their entireties.

TECHNICAL FIELD AND BACKGROUND OF INVENTION

The present invention relates to the field of containers and to thefield of insulated containers. More particularly, the present inventionrelates to the field of insulated shipping containers utilizingsustainable materials including recycled post-industrial, pre-consumernatural fiber. The containers according to the present invention may beused in transporting and storing objects which may be at a temperaturethat is different from the temperature outside the container.

Temperature sensitive products need to be transported from time to time.For instance, certain medications may need to be kept cool relative totemperatures outside of the container. In other instances, food may needto be kept warm relative to temperatures outside of the container. As aresult of these needs, packaging has been designed to maintain aninternal temperature according to the requirements of the product. Somepackaging may utilize electro-mechanical devices such as refrigeration,heat exchangers, or heat sinks in order to provide a required steadytemperature. Other packaging may utilize foams, plastics, and otherpolymers along with cool packs, water ice, or dry ice in order tomaintain the required temperature environment inside the packaging.

However, many of these packages and devices are expensive and heavy (aswith the refrigeration and heat sinks) or are harmful to the environment(as with some refrigeration and also the foams and plastics) or both.Because of these problems, some have devised products which may be madefrom post-consumer waste such as recycled cotton gathered from usedclothing. However, these products may be prone to contamination fromyarn dies, applied chemicals, and other contaminants which the clothingmay have acquired during the period of use. The post-consumer materialmust be cleaned and shredded ahead of reprocessing, however, thisprocess does not eliminate yarn dies and the possibility ofcontaminants. Most post-consumer waste retains a blue colorization afterprocessing. Therefore, because of the contamination and residualcolorization issues these products require that any insulationmanufactured from post-consumer cotton be wrapped in another materialsuch as plastic. This use of plastic and other barriers undermines theenvironmental incentive for using a recycled product by posingadditional environmental concerns. It may also further add to themanufacturing costs.

Accordingly, there is a long felt need in the art for a packagingmaterial which affords safe transportation of temperature sensitivematerials, which has a consistent density, which maintains an ininternal temperature relative an external temperature, which isefficiently and economically manufactured, which is lightweight, andwhich minimizes negative impacts to the environment.

SUMMARY OF THE INVENTION

The present invention is an insulated shipping container which affordssafe transportation of temperature sensitive products, which has aconsistent density, which maintains an in internal temperature relativeto an external temperature, which is efficiently and economicallymanufactured, which is lightweight, and which minimizes negative impactsto the environment.

The present invention utilizes post-industrial, pre-consumer cottonwaste. Post-industrial, pre-consumer cotton waste may include fibermaterial gleaned and/or trimmed as part of cotton manufacturing, andconverting process.

Such fiber material, collected from the manufacturing process, maycontain small pieces of cotton seed pods and stems removed as part ofthe manufacturing process. These fiber materials have not been convertedinto finished products (such as clothing or other fabrics). Thus, thepresent invention is directed to an insulated shipping containerutilizing unwrapped cotton waste as the thermal insulating layer.

However, the invention is not limited only to waste generated from asingle manufacturing or converting process. As such, post-industrial,pre-consumer waste may be from raw cotton processing, cotton yarnmanufacturing, cotton fabric manufacturing and related processes such ascarding, airlay, garneting, and other similar methods of manufacturing.

According to one aspect of the invention, the use of polyethylene filmwrapped around pads manufactured from cotton waste can be eliminated. Nowrapping is required by the present invention and exposed fibers alonecan be utilized. Because the fibers are pre-consumer, according to thepresent invention, the risk of cross contamination from post-consumerrecycled products is eliminated.

Alternatively, a natural fiber lamination may be applied to surfaces inorder to provide a smoother surface wherein images and indicia may beapplied. The elimination of poly wrap may provide an environmentalbenefit and also be a cost saving measure. The entirety of theinsulation layer, whether including fibers alone or also including thelaminated layer is biodegradable in anaerobic environments.

According to one embodiment of the invention, the insulating layer mayhave applied to it one or more natural fiber lamination layers. Thenatural fiber lamination layer may be applied to an outer surface of theinsulating layer which may be a contact surface. In some embodiments,the natural fiber lamination layer may be applied to only one surface ormay be applied to two surfaces but need not be applied to side edgesurfaces.

According to one embodiment of the invention, an insulated container mayinclude a rigid container surrounding an insulation layer formed from apost-industrial cotton waste. The insulation layer may be characterizedby a lack of any wrapping material.

According to another embodiment of the invention, the rigid containermay be made from cardboard.

According to another embodiment of the invention, the rigid containermay be made from plastic. The plastic may be a reusable plastic.

According to another embodiment of the invention, the insulation layermay include a pair of interlocking C-shaped members forming an enclosedcube shaped cavity. The interior of the cube may form an interiorportion of the insulated container.

According to another embodiment of the invention, the interlockingC-shaped members, referred to as an “A” and a “B” pad, may have a topportion which is integrally and hingedly formed in the member forproviding access to an interior portion of the insulated container.

According to a method of practicing the invention, an insulatedcontainer may be manufactured by providing a rigid container andproviding a quantity of post-industrial cotton waste. Thispost-industrial cotton waste may then be processed into a fiber sheet.The sheet made from the waste may be formed using a variety ofconverting processes including, carding, airlay, and needle punch toachieve a specified thickness and density. Next, the sheet may be cutinto rectangular sections. A pair of sections may be arranged to forminterlocking C-shaped members. The pair of sections, referred to as an“A” pad and a “B” pad, may then be placed into the rigid container.

According to another aspect of the method, the method may furtherinclude the step of laminating a natural fiber lamination layer to thefiber sheet.

According to another aspect of the method, the cotton waste includescotton waste generated from one or more of cotton processing, cottonmanufacturing, and/or cotton converting.

According to another aspect of the method, the insulation layer iscapable of maintaining a constant internal temperature for 48 hourswhere three 500 ML and two 250 ML IV bags are cooled by four 24 ozfrozen ice packs placed at the top and bottom below a payload.

According to another aspect of the method, the insulation layer isbiodegradable in an anaerobic environment.

According to another aspect of the invention, both the rigid containerand the pair of sections of the insulation layer may be provided to anend user in sheet form and may be assembled into the insulated containerby the end user.

According to another embodiment of the invention, the insulatedcontainer may include an insulation layer formed from a post-industrial,pre-consumer cotton waste, a rigid cardboard container surrounding theinsulation layer, and a natural fiber lamination layer applied to acontact surface of the insulation layer. According to such anembodiment, the cotton waste may include cotton waste generated from oneor more of cotton processing, cotton manufacturing, and/or cottonconverting. According to such an embodiment, the insulation layer may bebiodegradable in an anaerobic environment. According to such anembodiment, the insulation layer may be capable of maintaining aconstant internal temperature for 48 hours where three 500 ML and two250 ML IV bags are cooled by four 24 oz frozen ice packs placed at thetop and bottom below a payload.

According to one embodiment, the term biodegradable may mean that theinsulation layer will biodegrade completely within one year or less whensubjected to the biodegration dynamics contained in ASTM D5511.According to the ASTM D5511 protocol, test reaction mixture consisted of10% shredded nitrile gloves, 10% Trypticase Soy Broth, 10%Thioglycollate medium, 60% municipal solid waste, and inoculated withconcentrated inoculum (1.2×106 CFU/ml) of aerobic and anaerobic mixedculture in 0.01 M phosphate buffer at pH 7.2 placed in aerobic andanaerobic glass digesters, and incubated at 37.5°. Positive controlsconsisted of reaction mixture above with lab-grade cellulose (100%,Aldrich) instead of shredded test sample(s) while negative controlscontained EDTA lab-grade (100%, Aldrich) instead of shredded testsample(s) in the test above. Reaction mixture was monitored at leastdaily, often more frequently, and sampled weekly for CO2 production,trapped in 3 KOH bottles connected in series, over a period of 15 weekswhen cumulative CO2 production was observed. Biodegradation was deemedto be positive (passed P test, 95 or >95% biodegradation) or negative(failed test, 5 or <5% biodegradation), based on carbon conversion.Percentages (%), actual observed versus theoretical possible—based ontotal carbon content—were determined on a dry weight basis.

BRIEF DESCRIPTION OF THE FIGURES

Features, aspects and advantages of the present invention are understoodwhen the following detailed description of the invention is read withreference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a prior art insulated container wherethe insulating material is expanded polystyrene foam;

FIG. 2 is a perspective view of a prior art insulated container wherethe insulating material is enclosed in plastic;

FIG. 3 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 4 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 5 is an exploded view of the insulated container in an unassembledstate;

FIG. 6 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 7 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 8 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 9 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 10 is an exploded view of the insulated container in a partiallyassembled state;

FIG. 11 is a perspective view of the insulated container in an assembledstate;

FIG. 12 is a perspective view of the insulated container in an assembledstate;

FIG. 12A is sectional view of the insulated container;

FIG. 13 is an exploded view of the insulated container in a partiallyassembled state and where the insulation layer does not include thenatural fiber lamination;

FIG. 14 is a heat stress chart;

FIG. 15 is a heat stress chart; and

FIG. 16 is a cold stress chart.

DETAILED DESCRIPTION

FIG. 1 and FIG. 2 show prior art insulated containers. In particular,FIG. 1 shows a prior art insulated container having a rigid foaminsulation layer. FIG. 2 shows a prior art insulated container having aninsulation layer which is wrapped in plastic.

Generally, FIGS. 3 through 10, show embodiments of the invention withinsulation layer 20 having a natural fiber lamination layer 26 appliedto contact surfaces. The contact surfaces are surfaces which may comeinto contact with contents of the container. Generally, FIG. 13 shows analternate embodiment of the invention where there is no natural fiberlamination layer and the fibers of the insulation layer 20 are exposedto the contents of the container. The embodiment utilizing the naturallamination layer 26 may be preferred to the embodiment of FIG. 13 when ashipper desires that the contents not come into contact with theinsulation layer, such as when shipping raw, unwrapped produce. Thenatural fiber lamination layer 26 is sustainable and is biodegradable.The natural fiber lamination layer 26 thus provides a helpful option tocompanies seeking a smoother, more consistent surface. The natural fiberlamination layer 26 may be made from a coffee filter paper, kraft paper,and the like. Text and images (not shown) may be printed on thelamination layer 26.

Referring to FIG. 3, an insulated container 10 is shown in a partiallyassembled state. The insulated container 10 includes rigid container 50and insulation layer 20. The rigid container 50 may be a cardboard boxas shown. The insulation layer 20 is made from cotton waste. The cottonwaste is processed into a sheet formed using a variety of convertingprocesses including, carding, airlay, and needle punch to form anon-woven sheet. The insulation layer 20 is formed to maintain uniformdensity and of a thickness optimized for particular applications.

The sheet may then be cut into rectangles which may be bent into a pairof C-shaped members, 22, 24. The first C-shaped member, referred to asan “A” pad 22 forms lid portion 30 which is connected to back sideportion 32 via first hinge portion 31. Bottom portion 34 is connected toback portion 32 via second hinge portion 33.

Similarly, the second C-shaped member, referred to as a “B” pad 24 formsfirst side portion 40 which is connected to front side portion 24 viahinge 41. Second side portion 44 is connected to front side portion 24via hinge portion 43.

When assembled, as shown in FIG. 4, second C-shaped member 24 fits intoa cavity formed by first C-shaped member 22 to form the interlockingC-shapes of the insulation layer 20. As shown in FIGS. 5-10, theinsulation layer 20 of the insulated container 10 may be assembled byfolding respective C-shaped members 22, 24. As shown in FIG. 5, theC-shaped members 22, 24 may have in unfolded state that is a flatrectangular shape. As shown in FIGS. 6-9, hinges 31, 33 and 41, 43 maybe formed by folding. These folds separate the portions 30, 32, 34, 40,42, 44 of each C-shaped member 22, 24.

FIG. 11 shows the fully assembled insulated container 10 with the lid ofthe rigid container 50 open. FIG. 12 visualized the cross-section A-Awhich is shown in FIG. 12A. In particular, the cross section A-A showsthe insulation layer 20 inside the rigid container 50. The natural fiberlamentation layer 26 is shown on the contact surfaces. Importantly,there is no plastic or non-biodegradable layer between the insulationlayer 20 and the rigid container 50 as is present in the prior art ofFIG. 2. That is, there is no additional plastic housing surrounding theinsulation layer 20. Both to the rigid container 50 and the internalcavity of the insulate container.

FIG. 13 shows the insulated container 10 of FIGS. 3-12A but where thenatural fiber insulation layer has not been added during themanufacturing process. Accordingly, the cotton waste of the insulationlayer 20 is exposed.

An embodiment of the invention may be created wherein the container iscapable of maintaining a constant internal temperature for 48 hourswhere three 500 ML and two 250 ML IV bags are cooled by four 24 ozfrozen ice packs. The ice packs are placed at the top and bottom belowthe payload. FIG. 14 shows heat stress test results which were recordedby individual data loggers within and outside the test package as wellas in proximity to the IV bags. The top line shows the ambienttemperature outside the insulated container. The other lines show“wrapped white cotton” “molded 1.5 inch foam” and “unwrapped whitecotton.”

Another embodiment of the invention may be created wherein the containeris capable of maintaining a constant internal temperature for 48 hourswhere six 600 ML IV bags are cooled by four 24 oz frozen ice packs. Theice packs are placed at the top and bottom below the payload. FIG. 15shows heat stress test results which were recorded by individual dataloggers within and outside the test package as well as in proximity tothe IV gabs. The top line shows the ambient temperature outside theinsulated container. The lower line shows the internal temperature.

Another embodiment of the invention may be created wherein the containeris capable of maintaining a constant internal temperature for 48 hourswhere six 600 ML IV bags are cooled by two 24 oz frozen ice packs andtwo 24 oz ambient ice packs. The ice packs are placed at the top andbottom below the payload. FIG. 16 shows cold stress test results whichwere recorded by individual data loggers within and outside the testpackage as well as in proximity to the IV gabs. The top line shows theambient temperature outside the insulated container. The lower lineshows the internal temperature.

Another embodiment may be created where the insulated container 10complies with test scope protocol ISTA 7D such that it maintainstemperature above 2° C. and below 8° C., without freezing, in simulatedsummer/heat stress conditions for a 48 hour distribution cycle.According to the ISTA 7D test, six 24 oz gel ice packs were added to theinsulated container 10 with a payload of six 500 mL IV bags (LactatedRinger's Solution USP), conditioned to 3° C.

Another embodiment may be created where the insulated container 10complies with test scope protocol ISTA 7D such that it maintainstemperature above 2° C. and below 8° C., without freezing, in simulatedwinter/cold stress conditions for a 48 hour distribution cycle.According to the ISTA 7D test, four 24 oz gel ice packs were added tothe insulated container 10 with a payload of ten 500 mL IV bags(Lactated Ringer's Solution USP), condition to 3° C.

An insulated container 10 according to the invention has been describedwith reference to specific embodiments and examples. Various details ofthe invention may be changed without departing from the scope of theinvention. Furthermore, the foregoing description of the preferredembodiments of the invention and best mode for practicing the inventionare provided for the purpose of illustration only and not for thepurpose of limitation, the invention being defined by the claims. It isenvisioned that other embodiments may perform similar functions and/orachieve similar results. Any and all such equivalent embodiments andexamples are within the scope of the present invention and are intendedto be covered by the appended claims.

What is claimed is:
 1. A method of making an insulated containercomprising the steps of: a. providing a rigid container; b. providing aquantity of post-industrial, pre-consumer cotton waste; c. processingthe post-industrial cotton waste into a sheet; d. converting the wastevia one or more converting processes including: carding, airlay, andneedle punch to achieve a specified thickness and density; d. cuttingthe sheet into rectangular sections; e. forming the rectangular sectionsinto interlocking C-shaped members; and f. placing the interlockingC-shaped into the rigid container.
 2. The method of claim 1 furthercomprising the step of laminating a natural fiber lamination layer tothe sheet.
 3. The method of claim 2 wherein the cotton waste includescotton waste generated from one or more of cotton processing, cottonmanufacturing, and/or cotton converting.
 4. The method of claim 2wherein the insulation layer is capable of maintaining a constantinternal temperature for 48 hours where three 500 ML and two 250 ML IVbags are cooled by four 24 oz frozen ice packs placed at the top andbottom below a payload.
 5. The method of claim 12 wherein the insulationlayer is biodegradable in an anaerobic environment.